EP3684697B1 - Kompensation der qualität von verpackungsmaterial - Google Patents

Kompensation der qualität von verpackungsmaterial

Info

Publication number
EP3684697B1
EP3684697B1 EP18858849.5A EP18858849A EP3684697B1 EP 3684697 B1 EP3684697 B1 EP 3684697B1 EP 18858849 A EP18858849 A EP 18858849A EP 3684697 B1 EP3684697 B1 EP 3684697B1
Authority
EP
European Patent Office
Prior art keywords
packaging material
wrap
load
sensing
indications
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP18858849.5A
Other languages
English (en)
French (fr)
Other versions
EP3684697A4 (de
EP3684697A1 (de
Inventor
Iii Patrick R. Lancaster
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Lantech com LLC
Original Assignee
Lantech com LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lantech com LLC filed Critical Lantech com LLC
Priority to SM20250335T priority Critical patent/SMT202500335T1/it
Publication of EP3684697A1 publication Critical patent/EP3684697A1/de
Publication of EP3684697A4 publication Critical patent/EP3684697A4/de
Application granted granted Critical
Publication of EP3684697B1 publication Critical patent/EP3684697B1/de
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B11/00—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material
    • B65B11/006—Helical strip wrapping combined with roping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B11/00—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material
    • B65B11/02—Wrapping articles or quantities of material, without changing their position during the wrapping operation, e.g. in moulds with hinged folders
    • B65B11/025—Wrapping articles or quantities of material, without changing their position during the wrapping operation, e.g. in moulds with hinged folders by webs revolving around stationary articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B11/00—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material
    • B65B11/04—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material the articles being rotated
    • B65B11/045—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material the articles being rotated by rotating platforms supporting the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B41/00—Supplying or feeding container-forming sheets or wrapping material
    • B65B41/12—Feeding webs from rolls
    • B65B41/16—Feeding webs from rolls by rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B57/00—Automatic control, checking, warning, or safety devices
    • B65B57/02—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of binding or wrapping material, containers, or packages
    • B65B57/04—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of binding or wrapping material, containers, or packages and operating to control, or to stop, the feed of such material, containers, or packages
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B57/00—Automatic control, checking, warning, or safety devices
    • B65B57/10—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged
    • B65B57/12—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged and operating to control, or stop, the feed of wrapping materials, containers, or packages
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B57/00—Automatic control, checking, warning, or safety devices
    • B65B57/10—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged
    • B65B57/14—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged and operating to control, or stop, the feed of articles or material to be packaged
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B57/00—Automatic control, checking, warning, or safety devices
    • B65B57/18—Automatic control, checking, warning, or safety devices causing operation of audible or visible alarm signals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H23/00—Registering, tensioning, smoothing or guiding webs
    • B65H23/04—Registering, tensioning, smoothing or guiding webs longitudinally
    • B65H23/044—Sensing web tension
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H23/00—Registering, tensioning, smoothing or guiding webs
    • B65H23/04—Registering, tensioning, smoothing or guiding webs longitudinally
    • B65H23/18—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web
    • B65H23/182—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web in unwinding mechanisms or in connection with unwinding operations
    • B65H23/185—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web in unwinding mechanisms or in connection with unwinding operations motor-controlled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H23/00—Registering, tensioning, smoothing or guiding webs
    • B65H23/04—Registering, tensioning, smoothing or guiding webs longitudinally
    • B65H23/18—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web
    • B65H23/188—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web in connection with running-web
    • B65H23/192—Registering, tensioning, smoothing or guiding webs longitudinally by controlling or regulating the web-advancing mechanism, e.g. mechanism acting on the running web in connection with running-web motor-controlled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B11/00—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material
    • B65B2011/002—Prestretching mechanism in wrapping machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B2210/00—Specific aspects of the packaging machine
    • B65B2210/14—Details of wrapping machines with web dispensers for application of a continuous web in layers onto the articles
    • B65B2210/16—Details of wrapping machines with web dispensers for application of a continuous web in layers onto the articles the web dispenser travelling around the article along a non-rotating ring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B2210/00—Specific aspects of the packaging machine
    • B65B2210/14—Details of wrapping machines with web dispensers for application of a continuous web in layers onto the articles
    • B65B2210/18—Details of wrapping machines with web dispensers for application of a continuous web in layers onto the articles the web dispenser being mounted on a rotary ring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B2210/00—Specific aspects of the packaging machine
    • B65B2210/14—Details of wrapping machines with web dispensers for application of a continuous web in layers onto the articles
    • B65B2210/20—Details of wrapping machines with web dispensers for application of a continuous web in layers onto the articles the web dispenser being mounted on a rotary arm
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2301/00—Handling processes for sheets or webs
    • B65H2301/50—Auxiliary process performed during handling process
    • B65H2301/54—Auxiliary process performed during handling process for managing processing of handled material
    • B65H2301/542—Quality control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2511/00—Dimensions; Position; Numbers; Identification; Occurrences
    • B65H2511/50—Occurence
    • B65H2511/52—Defective operating conditions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2511/00—Dimensions; Position; Numbers; Identification; Occurrences
    • B65H2511/50—Occurence
    • B65H2511/52—Defective operating conditions
    • B65H2511/521—Presence of foreign object or undesirable material, i.e. material of another nature than the handled material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2515/00—Physical entities not provided for in groups B65H2511/00 or B65H2513/00
    • B65H2515/84—Quality; Condition, e.g. degree of wear
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2553/00—Sensing or detecting means
    • B65H2553/30—Sensing or detecting means using acoustic or ultrasonic elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2553/00—Sensing or detecting means
    • B65H2553/40—Sensing or detecting means using optical, e.g. photographic, elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2553/00—Sensing or detecting means
    • B65H2553/40—Sensing or detecting means using optical, e.g. photographic, elements
    • B65H2553/42—Cameras
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/10—Handled articles or webs
    • B65H2701/12—Surface aspects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/10—Handled articles or webs
    • B65H2701/19—Specific article or web
    • B65H2701/1944—Wrapping or packing material

Definitions

  • the invention generally relates to wrapping loads with packaging material through relative rotation of loads and a packaging material dispenser.
  • One system uses wrapping machines to stretch, dispense, and wrap packaging material, e.g., film, around a load.
  • the packaging material may be pre-stretched before it is applied to the load.
  • Wrapping can be performed as an inline, automated packaging technique that dispenses and wraps packaging material in a stretch condition around a load on a pallet to cover and contain the load.
  • Stretch wrapping whether accomplished by a turntable, rotating arm, vertical rotating ring, or horizontal rotating ring, typically covers the four vertical sides of the load with a stretchable packaging material such as polyethylene packaging material. In each of these arrangements, relative rotation is provided between the load and the packaging material dispenser to wrap packaging material about the sides of the load.
  • Film breaks are one of the most frequent and problematic sources of machine downtime and loss of "centerline" wrapper settings to a standard. Film breaks have many causes inherent to the wrapping process that can be mitigated, including, for example, irregularities or sharp points in the load or pallet, mechanical issues with rollers and clamps, electronic control issues around maintenance of film or packaging material tension during start, acceleration, and ending of a wrap operation or cycle, etc. These various causes of film breaks may be mitigated in many instances with more effective handling of the wrapping process.
  • film breaks are also impacted by fluctuations in the packaging material quality, where random and unpredictable changes in packaging material characteristics (often within a single packaging material roll) can cause a packaging material's resistance to film breaks to be reduced. Random flaws in a packaging material web such as gels, carbon particles, gauge band including shipping and handling damage to the packaging material roll remain problematic since they are generally difficult to sense or predict.
  • US 2017/088301 A1 discloses a method controlling a load wrapping apparatus wherein some packaging material characteristics, indicating a change in packaging material quality, are sensed during the wrapping operation and, accounting for the sensed value of those characteristics associated with a risk of film breaks, wrapping parameters are changed.
  • the invention addresses these and other problems associated with the art by providing a method, apparatus and program product that utilize packaging material quality compensation to sense changes in certain characteristics of a packaging material that can be associated with increased risks of film breaks, and automatically make certain changes in machine settings to mitigate the impact of those enhanced risks.
  • a method of controlling a load wrapping apparatus of the type configured to wrap a load with packaging material dispensed from a packaging material dispenser through relative rotation between the packaging material dispenser and the load may include sensing one or more indications of changes in packaging material characteristics during one or more wrap operations, and changing one or more wrap parameters used to wrap the load in response to sensing the one or more indications.
  • changing the one or more wrap parameters optimizes load wrapping apparatus performance and/or packaging material cost. In addition, in some embodiments changing the one or more wrap parameters reduces an incidence of film breaks.
  • sensing the one or more indications is performed by a sensor array in a pre-stretch zone of the packaging material dispenser. In some embodiments, sensing the one or more indications includes sensing a gel on the packaging material with an image sensor directed at a web of the packaging material. In addition, in some embodiments, sensing the one or more indications includes sensing a hole in the packaging material with an ultrasonic sensor directed at a web of the packaging material, and in some embodiments, sensing the one or more indications includes sensing a force to pre-stretch at a given payout percentage with a force sensor coupled to an idle roller disposed between upstream and downstream dispensing rollers of a pre-stretch assembly.
  • sensing the one or more indications includes sensing a tension at a given payout percentage with a force sensor coupled to an idle roller disposed downstream of a pre-stretch assembly, and in some embodiments, sensing the one or more indications includes sensing an unwind force on a packaging material supply roll with a force sensor coupled upstream of a pre-stretch assembly. Further, in some embodiments, sensing the one or more indications includes sensing a visible packaging material roll surface with an image sensor.
  • Some embodiments also include sensing a cessation of the one or more indications of changes in packaging material characteristics, and changing the one or more wrap parameters in response to sensing the cessation.
  • changing the one or more wrap parameters in response to sensing the cessation includes restoring the one or more wrap parameters to original values.
  • sensing the one or more indications of changes in packaging material characteristics is performed during a first wrap operation, and changing the one or more wrap parameters used to wrap the load in response to sensing the one or more indications is performed during a second wrap operation.
  • sensing the one or more indications of changes in packaging material characteristics and changing the one or more wrap parameters used to wrap the load in response to sensing the one or more indications are performed during the same wrap operation.
  • a method of controlling a load wrapping apparatus of the type configured to wrap a load on a load support with packaging material dispensed from a packaging material dispenser through relative rotation between the packaging material dispenser and the load support may include sensing one or more indications of changes in packaging material characteristics during one or more wrap operations and indicative of a decrease in quality in the packaging material, changing one or more wrap parameters used to wrap the load in response to sensing the one or more indications, thereafter sensing a cessation of the one or more indications of changes in packaging material characteristics, and changing the one or more wrap parameters in response to sensing the cessation.
  • changing the one or more wrap parameters in response to sensing the cessation includes restoring the one or more wrap parameters to original values.
  • an apparatus for wrapping a load with packaging material may include a packaging material dispenser for dispensing packaging material to the load, a rotational drive configured to generate relative rotation between the packaging material dispenser and the load about a center of rotation, and a controller coupled to the packaging material dispenser and the rotational drive and configured to sense one or more indications of changes in packaging material characteristics during one or more wrap operations, and change one or more wrap parameters used to wrap the load in response to sensing the one or more indications, and wrap the load using the changed one or more wrap parameters.
  • the processor is in a controller of the load wrapping apparatus, and the apparatus further includes a packaging material dispenser for dispensing packaging material to the load, while in some embodiments, the processor is in a device external to the load wrapping apparatus.
  • the device is a mobile device, a single-user computer or a multi-user computer.
  • FIG. 1 illustrates a rotating arm-type wrapping apparatus 100, which includes a roll carriage or elevator 102 mounted on a rotating arm 104.
  • Roll carriage 102 may include a packaging material dispenser 106.
  • Packaging material dispenser 106 may be configured to dispense packaging material 108 as rotating arm 104 rotates relative to a load 110 to be wrapped.
  • packaging material dispenser 106 may be configured to dispense stretch wrap packaging material.
  • stretch wrap packaging material is defined as material having a high yield coefficient to allow the material a large amount of stretch during wrapping.
  • packaging material that will not be pre-stretched prior to application to the load.
  • packaging material include netting, strapping, banding, tape, etc.
  • the invention is therefore not limited to use with stretch wrap packaging material.
  • packaging material web
  • film film
  • packaging material web may be used interchangeably.
  • breakage of any of the aforementioned types of packaging materials will hereinafter be referred to as “film breaks,” so the term should not be interpreted to imply that film breaks refer only to breakages occurring in film-type packaging material webs.
  • Packaging material dispenser 106 may include a pre-stretch assembly 112 configured to pre-stretch packaging material before it is applied to load 110 if pre-stretching is desired, or to dispense packaging material to load 110 without pre-stretching.
  • Pre-stretch assembly 112 may include at least one packaging material dispensing roller, including, for example, an upstream dispensing roller 114 and a downstream dispensing roller 116. It is contemplated that pre-stretch assembly 112 may include various configurations and numbers of pre-stretch rollers, drive or driven roller and idle rollers without departing from the scope of the invention as defined in the appended claims.
  • upstream and downstream are intended to define positions and movement relative to the direction of flow of packaging material 108 as it moves from packaging material dispenser 106 to load 110. Movement of an object toward packaging material dispenser 106, away from load 110, and thus, against the direction of flow of packaging material 108, may be defined as “upstream.” Similarly, movement of an object away from packaging material dispenser 106, toward load 110, and thus, with the flow of packaging material 108, may be defined as “downstream.” Also, positions relative to load 110 (or a load support surface 118) and packaging material dispenser 106 may be described relative to the direction of packaging material flow.
  • the pre-stretch roller closer to packaging material dispenser 106 may be characterized as the "upstream” roller and the pre-stretch roller closer to load 110 (or load support 118) and further from packaging material dispenser 106 may be characterized as the "downstream” roller.
  • a packaging material drive system 120 including, for example, an electric motor 122, may be used to drive dispensing rollers 114 and 116.
  • electric motor 122 may rotate downstream dispensing roller 116.
  • Downstream dispensing roller 116 may be operatively coupled to upstream dispensing roller 114 by a chain and sprocket assembly, such that upstream dispensing roller 114 may be driven in rotation by downstream dispensing roller 116.
  • Other connections may be used to drive upstream roller 114 or, alternatively, a separate drive (not shown) may be provided to drive upstream roller 114.
  • the roll of packaging material 108 may be undriven and may rotate freely, while in other embodiments the roll may be driven, e.g., by biasing a surface of the roll against upstream dispensing roller 114 or another driven roller, or by driving the roll directly.
  • Downstream of downstream dispensing roller 116 may be provided one or more idle rollers 124, 126 that redirect the web of packaging material, with the most downstream idle roller 126 effectively providing an exit point 128 from packaging material dispenser 102, such that a portion 130 of packaging material 108 extends between exit point 128 and a contact point 132 where the packaging material engages load 110 (or alternatively contact point 132' if load 110 is rotated in a counter-clockwise direction).
  • Wrapping apparatus 100 also includes a relative rotation assembly 134 configured to rotate rotating arm 104, and thus, packaging material dispenser 106 mounted thereon, relative to load 110 as load 110 is supported on load support surface 118.
  • Relative rotation assembly 134 may include a rotational drive system 136, including, for example, an electric motor 138. It is contemplated that rotational drive system 136 and packaging material drive system 120 may run independently of one another. Thus, rotation of dispensing rollers 114 and 116 may be independent of the relative rotation of packaging material dispenser 106 relative to load 110. This independence allows a length of packaging material 108 to be dispensed per a portion of relative revolution that is neither predetermined nor constant. Rather, the length may be adjusted periodically or continuously based on changing conditions. In other embodiments, however, packaging material dispenser 106 may be driven proportionally to the relative rotation, or alternatively, tension in the packaging material extending between the packaging material dispenser and the load may be used to drive the packaging material dispenser.
  • Wrapping apparatus 100 may further include a lift assembly 140.
  • Lift assembly 140 may be powered by a lift drive system 142, including, for example, an electric motor 144, that may be configured to move roll carriage 102 vertically relative to load 110.
  • Lift drive system 142 may drive roll carriage 102, and thus packaging material dispenser 106, generally in a direction parallel to an axis of rotation between the packaging material dispenser 106 and load 110 and load support surface 118.
  • lift drive system 142 may drive roll carriage 102 and packaging material dispenser 106 upwards and downwards vertically on rotating arm 104 while roll carriage 102 and packaging material dispenser 106 are rotated about load 110 by rotational drive system 136, to wrap packaging material spirally about load 110.
  • One or more of downstream dispensing roller 116, idle roller 124 and idle roller 126 may include a corresponding sensor 146, 148, 150 to monitor rotation of the respective roller.
  • rollers 116, 124 and/or 126, and/or packaging material 108 dispensed thereby may be used to monitor a dispense rate of packaging material dispenser 106, e.g., by monitoring the rotational speed of rollers 116, 124 and/or 126, the number of rotations undergone by such rollers, the amount and/or speed of packaging material dispensed by such rollers, and/or one or more performance parameters indicative of the operating state of packaging material drive system 120, including, for example, a speed of packaging material drive system 120.
  • the monitored characteristics may also provide an indication of the amount of packaging material 108 being dispensed and wrapped onto load 110.
  • a sensor e.g., sensor 148 or 150, may be used to detect a break in the packaging material.
  • Wrapping apparatus also includes an angle sensor 152 for determining an angular relationship between load 110 and packaging material dispenser 106 about a center of rotation 154.
  • Angle sensor 152 may be implemented, for example, as a rotary encoder, or alternatively, using any number of alternate sensors or sensor arrays capable of providing an indication of the angular relationship and distinguishing from among multiple angles throughout the relative rotation, e.g., an array of proximity switches, optical encoders, magnetic encoders, electrical sensors, mechanical sensors, photodetectors, motion sensors, etc.
  • the angular relationship may be represented in some embodiments in terms of degrees or fractions of degrees, while in other embodiments a lower resolution may be adequate.
  • an angle sensor consistent with the invention may also be disposed in other locations on wrapping apparatus 100, e.g., about the periphery or mounted on arm 104 or roll carriage 102.
  • angular relationship may be represented and/or measured in units of time, based upon a known rotational speed of the load relative to the packaging material dispenser, from which a time to complete a full revolution may be derived such that segments of the revolution time would correspond to particular angular relationships.
  • Other sensors may also be used to determine the height and/or other dimensions of a load, among other information.
  • Sensor 156 may be implemented using various types of distance sensors, e.g., a photoeye, proximity detector, laser distance measurer, ultrasonic distance measurer, electronic rangefinder, and/or any other suitable distance measuring device.
  • exemplary distance measuring devices may include, for example, an IFM Effector 01D100 and a Sick UM30-213118 (6036923).
  • Film angle sensor 158 may be used to determine a film angle for portion 130 of packaging material 108, which may be relative, for example, to a radial (not shown in Fig. 1 ) extending from center of rotation 154 to exit point 128 (although other reference lines may be used in the alternative).
  • film angle sensor 158 may be implemented using a distance sensor, e.g., a photoeye, proximity detector, laser distance measurer, ultrasonic distance measurer, electronic rangefinder, and/or any other suitable distance measuring device.
  • a distance sensor e.g., a photoeye, proximity detector, laser distance measurer, ultrasonic distance measurer, electronic rangefinder, and/or any other suitable distance measuring device.
  • an IFM Effector 01D100 and a Sick UM30-213118 6036923 may be used for film angle sensor 158.
  • film angle sensor 158 may be implemented mechanically, e.g., using a cantilevered or rockered follower arm having a free end that rides along the surface of portion 130 of packaging material 108 such that movement of the follower arm tracks movement of the packaging material.
  • a film angle sensor may be implemented by a force sensor that senses force changes resulting from movement of portion 130 through a range of film angles, or a sensor array (e.g., an image sensor) that is positioned above or below the plane of portion 130 to sense an edge of the packaging material.
  • sensors 146, 148, 150, 152, 156, 158 may be omitted.
  • Wrapping apparatus 100 may also include additional components used in connection with other aspects of a wrapping operation.
  • a clamping device 159 may be used to grip the leading end of packaging material 108 between wrap operations or cycles.
  • a conveyor (not shown) may be used to convey loads to and from wrapping apparatus 100.
  • Other components commonly used on a wrapping apparatus will be appreciated by one of ordinary skill in the art having the benefit of the instant disclosure.
  • FIG. 2 An example schematic of a control system 160 for wrapping apparatus 100 is shown in Fig. 2 .
  • Motor 122 of packaging material drive system 120, motor 138 of rotational drive system 136, and motor 144 of lift drive system 142 may communicate through one or more data links 162 with a rotational drive variable frequency drive (“VFD") 164, a packaging material drive VFD 166, and a lift drive VFD 168, respectively.
  • VFD rotational drive variable frequency drive
  • Rotational drive VFD 164, packaging material drive VFD 166, and lift drive VFD 168 may communicate with controller 170 through a data link 172. It should be understood that rotational drive VFD 164, packaging material drive VFD 166, and lift drive VFD 168 may produce outputs to controller 170 that controller 170 may use as indicators of rotational movement.
  • Controller 170 in the embodiment illustrated in Fig. 2 is a local controller that is physically co-located with the packaging material drive system 120, rotational drive system 136 and lift drive system 142. Controller 170 may include hardware components and/or software program code that allow it to receive, process, and transmit data. It is contemplated that controller 170 may be implemented as a programmable logic controller (PLC), or may otherwise operate similar to a processor in a computer system. Controller 170 may communicate with an operator interface 174 via a data link 176. Operator interface 174 may include a display or screen and controls that provide an operator with a way to monitor, program, and operate wrapping apparatus 100.
  • PLC programmable logic controller
  • Controller 170 may also communicate with one or more sensors, e.g., sensors 152 and 156, among others, through a data link 178 to allow controller 170 to receive feedback and/or performance-related data during wrapping, such as roller and/or drive rotation speeds, load dimensional data, etc. It is contemplated that data links 162, 172, 176, and 178 may include any suitable wired and/or wireless communications media known in the art.
  • controller 170 may represent practically any type of computer, computer system, controller, logic controller, or other programmable electronic device, and may in some embodiments be implemented using one or more networked computers or other electronic devices, whether located locally or remotely with respect to the various drive systems 120, 136 and 142 of wrapping apparatus 100.
  • Controller 170 typically includes a central processing unit including at least one microprocessor coupled to a memory, which may represent the random access memory (RAM) devices comprising the main storage of controller 170, as well as any supplemental levels of memory, e.g., cache memories, non-volatile or backup memories (e.g., programmable or flash memories), read-only memories, etc.
  • the memory may be considered to include memory storage physically located elsewhere in controller 170, e.g., any cache memory in a processor in CPU 52, as well as any storage capacity used as a virtual memory, e.g., as stored on a mass storage device or on another computer or electronic device coupled to controller 170.
  • Controller 170 may also include one or more mass storage devices, e.g., a floppy or other removable disk drive, a hard disk drive, a direct access storage device (DASD), an optical drive (e.g., a CD drive, a DVD drive, etc.), and/or a tape drive, among others.
  • controller 170 may include an interface 190 with one or more networks 192 (e.g., a LAN, a WAN, a wireless network, and/or the Internet, among others) to permit the communication of information to the components in wrapping apparatus 100 as well as with other computers and electronic devices, e.g.
  • networks 192 e.g., a LAN, a WAN, a wireless network, and/or the Internet, among others
  • Controller 170 operates under the control of an operating system, kernel and/or firmware and executes or otherwise relies upon various computer software applications, components, programs, objects, modules, data structures, etc. Moreover, various applications, components, programs, objects, modules, etc. may also execute on one or more processors in another computer coupled to controller 170, e.g., in a distributed or client-server computing environment, whereby the processing required to implement the functions of a computer program may be allocated to multiple computers over a network.
  • routines executed to implement the embodiments of the invention will be referred to herein as "computer program code,” or simply "program code.”
  • Program code typically comprises one or more instructions that are resident at various times in various memory and storage devices in a computer, and that, when read and executed by one or more processors in a computer, cause that computer to perform the steps necessary to execute steps or elements embodying the various aspects of the invention.
  • Communication media may embody computer readable instructions, data structures or other program modules.
  • communication media may include wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of any of the above may also be included within the scope of computer readable media.
  • the hardware and software used to control wrapping apparatus 100 is assumed to be incorporated wholly within components that are local to wrapping apparatus 100 illustrated in Figs. 1-2 , e.g., within components 162-178 described above. It will be appreciated, however, that in other embodiments, at least a portion of the functionality incorporated into a wrapping apparatus may be implemented in hardware and/or software that is external to the aforementioned components. For example, in some embodiments, some user interaction may be performed using an external device such as a networked computer or mobile device, with the external device converting user or other input into control variables that are used to control a wrapping operation.
  • an external device such as a networked computer or mobile device
  • user interaction may be implemented using a web-type interface, and the conversion of user input may be performed by a server or a local controller for the wrapping apparatus, and thus external to a networked computer or mobile device.
  • a central server may be coupled to multiple wrapping stations to control the wrapping of loads at the different stations.
  • the operations of receiving user or other input, converting the input into control variables for controlling a wrap operation, initiating and implementing a wrap operation based upon the control variables, providing feedback to a user, etc. may be implemented by various local and/or remote components and combinations thereof in different embodiments.
  • an external device such as a mobile device, a networked computer, a server, a cloud service, etc.
  • wrap model may be generated that defines the control variables for controlling a wrap operation for a particular load, and that wrap model may then be communicated to a wrapping apparatus and used by a controller therefor to control a dispense rate during a wrap operation.
  • the invention is not limited to the particular allocation of functionality described herein.
  • Wrapping apparatus 200 may include elements similar to those shown in relation to wrapping apparatus 100 of Fig. 1 , including, for example, a roll carriage or elevator 202 including a packaging material dispenser 206 configured to dispense packaging material 208 during relative rotation between roll carriage 202 and a load 210 disposed on a load support 218.
  • a rotating ring 204 is used in wrapping apparatus 200 in place of rotating arm 104 of wrapping apparatus 100.
  • wrapping apparatus 200 may operate in a manner similar to that described above with respect to wrapping apparatus 100.
  • Packaging material dispenser 206 may include a pre-stretch assembly 212 including an upstream dispensing roller 214 and a downstream dispensing roller 216, and a packaging material drive system 220, including, for example, an electric motor 222, may be used to drive dispensing rollers 214 and 216.
  • Downstream of downstream dispensing roller 216 may be provided one or more idle rollers 224, 226, with the most downstream idle roller 226 effectively providing an exit point 228 from packaging material dispenser 206, such that a portion 230 of packaging material 208 extends between exit point 228 and a contact point 232 where the packaging material engages load 210.
  • Wrapping apparatus 200 also includes a relative rotation assembly 234 configured to rotate rotating ring 204, and thus, packaging material dispenser 206 mounted thereon, relative to load 210 as load 210 is supported on load support surface 218.
  • Relative rotation assembly 234 may include a rotational drive system 236, including, for example, an electric motor 238.
  • Wrapping apparatus 200 may further include a lift assembly 240, which may be powered by a lift drive system 242, including, for example, an electric motor 244, that may be configured to move rotating ring 204 and roll carriage 202 vertically relative to load 210.
  • wrapping apparatus 200 may include sensors 246, 248, 250 on one or more of downstream dispensing roller 216, idle roller 224 and idle roller 226.
  • an angle sensor 252 may be provided for determining an angular relationship between load 210 and packaging material dispenser 206 about a center of rotation 254, and in some embodiments, one or both of a load distance sensor 256 and a film angle sensor 258 may also be provided.
  • Sensor 252 may be positioned proximate center of rotation 254, or alternatively, may be positioned at other locations, such as proximate rotating ring 204.
  • Wrapping apparatus 200 may also include additional components used in connection with other aspects of a wrapping operation, e.g., a clamping device 259 may be used to grip the leading end of packaging material 208 between cycles.
  • Fig. 4 likewise shows a turntable-type wrapping apparatus 300, which may also include elements similar to those shown in relation to wrapping apparatus 100 of Fig. 1 .
  • wrapping apparatus 300 instead of a roll carriage or elevator 102 that rotates around a fixed load 110 using a rotating arm 104, as in Fig. 1 , wrapping apparatus 300 includes a rotating turntable 304 functioning as a load support 318 and configured to rotate load 310 about a center of rotation 354 (through which projects an axis of rotation that is perpendicular to the view illustrated in Fig. 4 ) while a packaging material dispenser 306 disposed on a roll carriage or elevator 302 remains in a fixed location about center of rotation 354 while dispensing packaging material 308.
  • wrapping apparatus 300 may operate in a manner similar to that described above with respect to wrapping apparatus 100.
  • Packaging material dispenser 306 may include a pre-stretch assembly 312 including an upstream dispensing roller 314 and a downstream dispensing roller 316, and a packaging material drive system 320, including, for example, an electric motor 322, may be used to drive dispensing rollers 314 and 316, and downstream of downstream dispensing roller 316 may be provided one or more idle rollers 324, 326, with the most downstream idle roller 326 effectively providing an exit point 328 from packaging material dispenser 306, such that a portion 330 of packaging material 308 extends between exit point 328 and a contact point 332 (or alternatively contact point 332' if load 310 is rotated in a counter-clockwise direction) where the packaging material engages load 310.
  • a packaging material drive system 320 including, for example, an electric motor 322
  • downstream of downstream dispensing roller 316 may be provided one or more idle rollers 324, 326, with the most downstream idle roller 326 effectively providing an exit point 328 from packaging material dispenser 306, such that a
  • Wrapping apparatus 300 also includes a relative rotation assembly 334 configured to rotate turntable 304, and thus, load 310 supported thereon, relative to packaging material dispenser 306.
  • Relative rotation assembly 334 may include a rotational drive system 336, including, for example, an electric motor 338.
  • Wrapping apparatus 300 may further include a lift assembly 340, which may be powered by a lift drive system 342, including, for example, an electric motor 344, that may be configured to move roll carriage or elevator 302 and packaging material dispenser 306 vertically relative to load 310.
  • wrapping apparatus 300 may include sensors 346, 348, 350 on one or more of downstream dispensing roller 316, idle roller 324 and idle roller 326.
  • an angle sensor 352 may be provided for determining an angular relationship between load 310 and packaging material dispenser 306 about a center of rotation 354, and in some embodiments, one or both of a load distance sensor 356 and a film angle sensor 358 may also be provided.
  • Sensor 352 may be positioned proximate center of rotation 354, or alternatively, may be positioned at other locations, such as proximate the edge of turntable 304.
  • Wrapping apparatus 300 may also include additional components used in connection with other aspects of a wrapping operation, e.g., a clamping device 359 may be used to grip the leading end of packaging material 308 between cycles.
  • Each of wrapping apparatus 200 of Fig. 3 and wrapping apparatus 300 of Fig. 4 may also include a controller (not shown) similar to controller 170 of Fig. 2 , and receive signals from one or more of the aforementioned sensors and control packaging material drive system 220, 320 during relative rotation between load 210, 310 and packaging material dispenser 206, 306.
  • packaging material characteristics may be impactful, including: packaging material "gels" as measured with a high speed video camera, packaging material holes as measured by an ultrasonic sensor (e.g., a Sick Ultrasonic UC4-11341 6034667 film sensor), force to pre-stretch the packaging material at a given payout percentage, e.g., as measured by a load cell on an intermediate idle roller, packaging material tension at a specific payout percentage, e.g., as measured by a load cell on a downstream idle roller, unwind force on packaging material from a supply roll, and visible packaging material roll surface (e.g., wrinkles, air entrapment, edge feather, gauge bands, etc.), among others.
  • These packaging material characteristics in some instances may be considered to be packaging material quality characteristics as they are indicative of the relative quality of a packaging material as compared to that packaging material's regular specifications.
  • changes may be made to mitigate specific combinations of packaging material changes as sensed in the manner discussed above, including: change in payout percentage or packaging material tension, change in pre-stretch percentage, and/or change in packaging material feed control.
  • an alert notification e.g., an alert banner
  • an alert banner may be generated to indicate to an operator the impact of the changes made.
  • a sensor array may be provided in a pre-stretch or other zone of a film delivery system or packaging material dispenser, and in response to detecting one or more changes in packaging material characteristics, automatic adjustments may be made to mitigate these changes in packaging material characteristics and potentially decrease the incidence of film breaks during wrapping.
  • a control system of a wrapping apparatus may receive one or more indications of changes in packaging material characteristics and may, in response, react to such indications with changes to one or more wrapping apparatus settings to optimize machine performance and/or packaging material cost.
  • Apparatus 400 may include a packaging material dispenser that dispenses a web of packaging material 402 from a roll 404 and past upstream and downstream dispensing rollers 406, 408 of a pre-stretch assembly, as well as between upstream and downstream idle rollers 410, 412 that are respectively disposed upstream and downstream of downstream dispensing roller 408.
  • a controller 414 controls a dispense rate of the packaging material dispenser by controlling a packaging material drive 416 coupled to downstream dispensing roller 408.
  • dispensing rollers 406 and 408 may be mechanically coupled to one another to rotate at a fixed or adjustable ratio relative to one another to provide a fixed or adjustable pre-stretch
  • dispensing roller 406 may be driven by a separate pre-stretch drive 418 that enables the pre-stretch ratio to be controlled electronically, and in some instances, dynamically during a wrap operation.
  • roll 404 may be unpowered, in other embodiments, including as shown in Fig. 5 , the roll may be driven by a drive 420, which in some embodiments may be configured as an electronic brake.
  • controller 414 may control drives 416, 418 and 420 to control the dispensation of packaging material from roll 404 to a load, which when coupled with control over a rotational drive 422 that controls relative rotation between the packaging material dispenser and the load, wraps packaging material around the load in a controlled manner.
  • load wrapping apparatus 400 including, for example, carriage control and various sensors used to detect various aspects of a wrap operation, may also be incorporated into load wrapping apparatus 400 but are not illustrated in Fig. 5 .
  • an image sensor 424 e.g., a high speed video camera or other suitable image sensor, which can be used to sense the presence of packaging material "gels" formed on the surface of the packaging material. Gels are generally unmelted plastic in a packaging material web that can cause breaks towards the center of the packaging material, and may be detectable from image data collected by image sensor 424, e.g., when positioned between upstream dispensing roller 406 and upstream idle roller 410, or in another suitable location.
  • image sensor 424 e.g., a high speed video camera or other suitable image sensor, which can be used to sense the presence of packaging material "gels" formed on the surface of the packaging material. Gels are generally unmelted plastic in a packaging material web that can cause breaks towards the center of the packaging material, and may be detectable from image data collected by image sensor 424, e.g., when positioned between upstream dispensing roller 406 and upstream idle roller 410, or in another suitable location.
  • force sensor 430 e.g., a load cell mechanically coupled to downstream idle roller 412 or another suitable arrangement for measuring tension (e.g., a dancer bar), to sense the tension in the packaging material between the downstream dispensing roller 408 and the load.
  • tension sensor 430 e.g., a load cell mechanically coupled to downstream idle roller 412 or another suitable arrangement for measuring tension (e.g., a dancer bar), to sense the tension in the packaging material between the downstream dispensing roller 408 and the load.
  • tension sensor e.g., a load cell mechanically coupled to downstream idle roller 412 or another suitable arrangement for measuring tension (e.g., a dancer bar), to sense the tension in the packaging material between the downstream dispensing roller 408 and the load.
  • Such a sensor may be used, for example, to sense packaging material tension at a given payout percentage or other wrap force parameter.
  • force sensor 432 e.g., a load cell mechanically coupled to dancer bar 434, or alternatively an idle roller, to sense the tension in the packaging material between the roll 404 and upstream dispensing roller 406, which is indicative of an unwind force on the packaging material from the roll.
  • an image sensor 436 e.g., a high speed video camera or other suitable image sensor, which can be used to sense the presence of defects on the surface of roll 404 and/or in the packaging material web 402 as it exits the roll, e.g., wrinkles, air entrapment, edge feather, gauge bands, die lines, nicked or torn edges, etc.
  • controller 414 may detect one or more characteristics of the packaging material associated with increased incidence of film breaks, and in response thereto, mitigate the risks by modifying one or more wrap parameters, e.g., to change a payout percentage, tension or other wrap force parameter (e.g., to vary the dispense rate controlled by packaging material drive 416 relative to the relative rotation rate controlled by rotational drive 422), to change a pre-stretch ratio or percentage (e.g., to vary the relative rates of rotation controlled by drives 416, 418), to change a packaging material feed control (e.g., to vary the drive or braking of roll 404 by drive 420), or various combinations thereof.
  • wrap parameters e.g., to change a payout percentage, tension or other wrap force parameter (e.g., to vary the dispense rate controlled by packaging material drive 416 relative to the relative rotation rate controlled by rotational drive 422), to change a pre-stretch ratio or percentage (e.g., to vary the relative rates of rotation controlled by drives 416, 418),
  • a wrap operation e.g., the carriage speed, the number of layers of packaging material, etc.
  • a parameter of a roping mechanism 438 which rolls or otherwise forms a rope along an edge of the packaging material web 402, may also be modified, e.g., to engage or disengage the mechanism, or to control an extent to which the edge of the web of packaging material is roped or rolled.
  • controller 414 may restore any previously-modified wrap parameters to their original values, or otherwise modify the wrap parameters from the values selected when attempting to mitigate the incidence of film breaks.
  • one or more wrap parameters may be modified from their original settings to decrease the likelihood of film breaks, and if later no gels are detected, the wrap parameters may be modified once again, but potentially to intermediate values that are not equal to the original values, but are still modified relative to those used when the gels were detected to accommodate the relatively higher risk that gels could be encountered on the same roll in the future.
  • Block 504 the various sensors utilized in load wrapping apparatus 400 may be monitored to detect the packaging material quality during the wrap operation, i.e., to attempt to detect one or more characteristics of the packaging material that are associated with increased incidences of film breaks.
  • Block 506 determines whether a negative change in packaging material quality has been detected, e.g., in response to sensing one or more characteristics exhibiting a greater risk of film breaks. If not, control passes to block 508 to determine whether a positive change in packaging material quality has been detected, e.g., in response to no longer sensing one or more characteristics exhibiting a greater risk of film breaks. If no changes have been detected in packaging material quality, block 508 passes control to block 510, which, so long as the wrap operation is not complete, passes control to block 504 to continue the wrap operation while continuing to monitor packaging material quality.
  • block 508 passes control to block 514 to restore one or more wrap parameters based upon the reduced risk of film breaks, and then to block 510 to continue with the wrap operation using the restored wrap parameters.
  • block 514 may simply restore original wrap parameters based upon a cessation of sensed indications of changes in packaging material characteristics. In other embodiments, however, block 514 may modify wrap parameters relative to those used to mitigate film breaks, while still using values that are different from the original wrap parameters.
  • Fig. 7 illustrates another example sequence of operations 520 suitable for execution by controller 414 of load wrapping apparatus 400 when performing a wrap operation.
  • the selected wrap parameters for the current wrap operation are obtained, and in block 524, a determination of whether any packaging material quality modifications are currently active, e.g., based upon the last wrap operation. If so, any active packaging material quality modifications are applied to the selected wrap parameters, e.g., to modify one or more of the selected wrap parameters to mitigate film break risks, and the wrap operation is initiated in block 528.
  • block 524 may bypass block 526, and proceed with the wrap operation using the selected wrap parameters.

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Claims (18)

  1. Verfahren zum Steuern einer Ladungsumhüllungsvorrichtung (100) des Typs, der dazu konfiguriert ist, eine Ladung (110) mit Verpackungsmaterial zu umhüllen, das von einem Verpackungsmaterialspender (106) durch relative Drehung zwischen dem Verpackungsmaterialspender (106) und der Ladung (110) ausgegeben wird, wobei das Verfahren umfasst:
    Erfassen eines oder mehrerer Anzeichen von Änderungen der Verpackungsmaterialeigenschaften während eines oder mehrerer Wickelvorgänge, wobei das eine oder die mehreren Anzeichen von Änderungen der Verpackungsmaterialeigenschaften auf eine Änderung der Verpackungsmaterialqualität hinweisen, die mit einem Risiko von Folienrissen verbunden ist, und wobei das eine oder die mehreren Anzeichen eine Verpackungsmaterialgelbildung, ein Verpackungsmaterialloch, eine Abwickelkraft auf einer Verpackungsmaterialvorratsrolle und/oder eine sichtbare Verpackungsmaterial-Rollenoberfläche umfassen; und
    Ändern eines oder mehrerer Wickelparameter, die zum Umwickeln der Ladung verwendet werden, als Reaktion auf das Erfassen der einen oder mehreren Anzeichen.
  2. Verfahren nach Anspruch 1, wobei die Anzeichen ferner eine Kraft zum Vordehnen bei einem gegebenen Ausgabeprozentsatz und/oder eine Spannung bei einem Ausgabeprozentsatz umfassen.
  3. Verfahren nach Anspruch 2, wobei die sichtbare Oberfläche der Verpackungsmaterialrolle eine oder mehrere der folgenden Stellen aufweist: Falten, Lufteinschlüsse, Randfedern, Randfehler, eingerissene Kanten, eingekerbte Kanten, Stanzlinien und/oder Spurweiten.
  4. Verfahren nach Anspruch 1, wobei der eine oder die mehreren Wickelparameter einen Ausgabeprozentsatz, eine Spannung, einen Vordehnungsprozentsatz, eine Verpackungsmaterialzufuhrsteuerung und/oder einen Seilbildungsmechanismusparameter umfassen, der die Seilbildung oder Rollenbildung einer Kante des Verpackungsmaterials steuert.
  5. Verfahren nach Anspruch 1, wobei das Erfassen der einen oder mehreren Anzeichen durch eine Sensoranordnung in einer Vordehnzone des Verpackungsmaterialspenders (106) erfolgt.
  6. Verfahren nach Anspruch 1, wobei das Erfassen der einen oder mehreren Anzeichen mindestens eines der folgenden umfasst:
    - Erfassen einer Gelbildung auf dem Verpackungsmaterial mit einem Bildsensor (424), der auf eine Bahn des Verpackungsmaterials gerichtet ist,
    - Erfassen eines Lochs im Verpackungsmaterial mit einem auf eine Bahn des Verpackungsmaterials gerichteten Ultraschallsensor (426),
    - Erfassen einer Vordehnkraft bei einem gegebenen Ausgabeprozentsatz mit einem Kraftsensor (428), der mit einer Leerlaufrolle gekoppelt ist, die zwischen den vor- und nachgelagerten Ausgaberollen einer Vordehnungsanordnung angeordnet ist,
    - Erfassen einer Spannung bei einem gegebenen Ausgabeprozentsatz mit einem Kraftsensor (430), der mit einer Leerlaufrolle gekoppelt ist, die einer Vordehnungsanordnung nachgelagert angeordnet ist,
    - Erfassen einer Abwickelkraft auf einer Verpackungsmaterial-Vorratsrolle mit einem Kraftsensor (432), der vor einer Vordehnungsanordnung angeschlossen ist,
    - Erfassen einer sichtbaren Oberfläche einer Verpackungsmaterialrolle mit einem Bildsensor (436).
  7. Verfahren nach Anspruch 1, das weiterhin umfasst:
    Erfassen eines Wegfalls der einen oder mehreren Anzeichen von Änderungen der Verpackungsmaterialeigenschaften; und
    Ändern des einen oder der mehreren Wickelparameter als Reaktion auf das Erkennen des Wegfalls, wobei das Ändern des einen oder der mehreren Wickelparameter als Reaktion auf das Erkennen des Wegfalls das Zurücksetzen des einen oder der mehreren Wickelparameter auf die ursprünglichen Werte umfasst.
  8. Verfahren nach Anspruch 1, wobei das Erfassen des einen oder der mehreren Anzeichen auf Änderungen der Verpackungsmaterialeigenschaften während eines ersten Wickelvorgangs erfolgt und das Ändern des einen oder der mehreren Wickelparameter, die zum Verpacken der Ladung verwendet werden, als Reaktion auf das Erfassen des einen oder der mehreren Anzeichen während eines zweiten Wickelvorgangs erfolgt.
  9. Verfahren nach Anspruch 1, wobei das Erfassen des einen oder der mehreren Anzeichen auf Änderungen der Verpackungsmaterialeigenschaften und das Ändern des einen oder der mehreren Verpackungsparameter, die zum Verpacken der Ladung verwendet werden, als Reaktion auf das Erfassen des einen oder der mehreren Anzeichen während desselben Verpackungsvorgangs durchgeführt werden.
  10. Verfahren nach Anspruch 1, wobei das eine oder die mehreren Änderungsanzeichen während eines ersten Wickelvorgangs unter den einen oder mehreren Wickelvorgängen erfasst werden und der eine oder die mehreren Wickelparameter während des ersten Wickelvorgangs geändert werden, um das Auftreten von Folienrissen zu verringern.
  11. Verfahren nach Anspruch 10, wobei das Ändern des Wickelparameters das Erhöhen einer Ausgaberate des Verpackungsmaterialspenders (106) als Reaktion auf das Erfassen der Anzeichen umfasst.
  12. Verfahren nach Anspruch 11, das ferner umfasst:
    Erfassen eines Wegfalls der Anzeichen der Änderung der Verpackungsmaterialeigenschaften; und
    Verringern der Abgaberate als Reaktion auf das Erkennen des Wegfalls;
    wobei das Erhöhen der Abgaberate das Erhöhen der Abgaberate über einen ersten Abgaberatenwert umfasst, bei dem der Verpackungsmaterialspender (106) durch eine Steuerung (170) der Ladungsverpackungsvorrichtung (100) gesteuert wird, und wobei das Ändern des Verpackungsparameters als Reaktion auf das Erfassen des Wegfalls das Zurücksetzen der Abgaberate auf den ersten Abgaberatenwert umfasst.
  13. Verfahren nach Anspruch 10, wobei der Wickelparameter einen Seilbildungsmechanismusparameter umfasst, der die Seilbildung oder Rollenbildung einer Kante des Verpackungsmaterials steuert, und wobei das Ändern des Wickelparameters das Aktivieren des Seilbildungsmechanismus (438) als Reaktion auf das Erfassen der Anzeichen umfasst.
  14. Verfahren nach Anspruch 1, wobei ein Loch im Verpackungsmaterial während eines ersten Wickelvorgangs unter den einem oder mehreren Wickelvorgängen erkannt wird; und
    eine Abgaberate des Verpackungsmaterialspenders während des ersten Wickelvorgangs und als Reaktion auf das Erkennen des Verpackungsmateriallochs erhöht wird, um das Auftreten von Folienrissen zu verringern.
  15. Vorrichtung, die einen Prozessor (52) und einen Programmcode umfasst, der bei Ausführung durch den Prozessor (52) so konfiguriert ist, dass er eine Ladungsverpackungsvorrichtung (100) des Typs steuert, der zum Verpacken einer Ladung (110) konfiguriert ist, wobei Verpackungsmaterial von einem Verpackungsmaterialspender (106) durch relative Drehung zwischen dem Verpackungsmaterialspender (106) und der Ladung (110) abgegeben wird, durch Ausführen des Verfahrens nach einem der Ansprüche 1-14.
  16. Vorrichtung nach Anspruch 15, wobei sich der Prozessor in einer Steuerung (170) der Vorrichtung zum Verpacken von Ladung (100) befindet und wobei die Vorrichtung ferner einen Verpackungsmaterialspender (106) zum Abgeben von Verpackungsmaterial an die Ladung (110) umfasst.
  17. Vorrichtung nach Anspruch 15, wobei sich der Prozessor (52) in einem Gerät außerhalb der Ladungsverpackungsvorrichtung (100) befindet und wobei das Gerät ein mobiles Gerät, ein Einzelbenutzercomputer oder ein Mehrbenutzercomputer ist.
  18. Programmprodukt, das ein nichtflüchtiges computerlesbares Medium und einen auf dem nichtflüchtigen computerlesbaren Medium gespeicherten Programmcode umfasst und dazu konfiguriert ist, eine Ladungsverpackungsvorrichtung (100) des Typs zu steuern, der dazu konfiguriert ist, eine Ladung (110) zu verpacken, wobei Verpackungsmaterial von einen Verpackungsmaterialspender (106) durch relative Drehung zwischen dem Verpackungsmaterialspender (106) und der Ladung (110) abgegeben wird, wobei der Programmcode so konfiguriert ist, dass er die Ladungsverpackungsvorrichtung (100) durch Ausführen eines der Verfahren der Ansprüche 1-14 steuert.
EP18858849.5A 2017-09-22 2018-09-21 Kompensation der qualität von verpackungsmaterial Active EP3684697B1 (de)

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US12037153B2 (en) 2024-07-16
CA3202731A1 (en) 2019-03-28
CA3076449C (en) 2023-08-08
US20200377250A1 (en) 2020-12-03
CA3076449A1 (en) 2019-03-28
WO2019058334A4 (en) 2019-05-16
US20230174261A1 (en) 2023-06-08
AU2018336150B2 (en) 2021-11-25
EP3684697A4 (de) 2021-06-16
SMT202500335T1 (it) 2025-11-10
EP3684697A1 (de) 2020-07-29

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